Air Lift 94412 Installation guide

Brand: Air Lift

Model: 94412

Type: Installation guide

Failure to read these instructions can

result in an incorrect installation.

For maximum effectiveness and safety,

please read these instructions completely

before proceeding with installation.

MN-1127 • Revision 012005 • ERN 9418

2009-2014 Ford Raptor

Kit 94412

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Info on Table of Contents page

Installation Guide

TABLE OF CONTENTS

Video-enhanced installation guides

Visit airliftcompany.com/workshop/category/install-videos to access our installation video archive*.

* subject to availability

System Overview ..................................... 2

Hardware and Tools ................................... 3

Introduction .......................................... 4

Notation Explanation ............................................................4

Installing the System .................................. 5

Installing the Assemblies ........................................................11

Installing the Air Lines .................................13

Installing the Heat Shield ........................................................ 14

Finished Installation ...................................15

Installation Checklist ...........................................................16

Maintenance and Use Guidelines .................................................16

Limited Warranty and Return Policy ......................17

MN-1127

System Overview

C OR D

E OR F

Passenger’s

(right) Side

Fig. 1

MN-1127

Missing or damaged parts? Call Air Lift customer

service at (800) 248-0892 for a replacement part.

Missing or damaged parts? Call Air Lift customer

service at (800) 248-0892 for a replacement part.

Hardware and Tools

Description ........................................................................... Qty

Hack saw or handheld grinder with a cut off wheel ...............................1

Tire marker, crayon or paint ....................................................................1

Standard and metric open-end or boxed wrenches ...........................Set

Standard and metric regular and deep-well sockets ..........................Set

Ratchet ................................................................................................... 1

9/16" Ratchet wrench .............................................................................1

Torque wrench ........................................................................................ 1

Standard and metric hex-key wrench (socket preferable) .....................1

Hose cutter, razor blade, or sharp knife ................................................. 1

Hoist and axle lift or floor jack ................................................................1

Tire chocks .............................................................................................2

Safety stands ..........................................................................................3

Safety glasses ........................................................................................1

Air compressor or compressed air source .............................................1

Spray bottle with dish soap/water solution ............................................ 1

Small wire brush ..................................................................................... 1

Item Part# Description ...................................................... Qty

A 01531 Clamp bar ............................................................. 2

B 03875 Lower bracket ....................................................... 2

C 07079 LH upper frame bracket ....................................... 1

D 07566 RH upper frame bracket ....................................... 1

E 07788 RH upper spring bracket ...................................... 1

F 07799 LH upper spring bracket ....................................... 1

G 11686 U-bolt .................................................................... 4

H 11967 Black roll plate ...................................................... 4

I 58996 Air spring with jounce bumper .............................. 2

J 21839 Straight fitting ....................................................... 2

K 17363 3/8"-24 x 3/4" Flat-head socket cap screw.......... 4

L 17284 3/8"-24 x 7/8" Hex cap screw .............................. 4

M 18504 3/8" Split lock washer ........................................... 4

N 18507 3/8" Flat washer .................................................... 4

O 17103 5/16"-18 x 1" Hex cap screw ............................... 1

P 17134 3/8"-16 x 1" Carriage bolt .................................... 4

Q 17490 3/8"-16 x 6 1/2" Carriage bolt .............................. 4

R 17366 M10 X 1.5 x 35 Button-head cap screw ............... 2

S 18203 9/16"-18 Deep nut ................................................ 8

T 18422 3/8"-16 Serrated flange lock nut .......................... 8

U 18433 5/16" Flat washer .................................................. 2

V 18438 5/16"-18 Nylon lock nut ........................................ 1

W 18444 3/8" Flat washer .................................................... 2

X 18635 9/16" Flat Washer ................................................. 8

AA* 20086 Air line ................................................................... 1

BB* 10466 Zip tie .................................................................... 6

CC* 18501 M8 Flat washer ..................................................... 2

DD* 21230 Valve cap .............................................................. 2

EE* 21234 Rubber washer ..................................................... 2

FF* 18411 Stainless steel star washer ................................... 2

GG* 21233 5/16" Hex nut ........................................................ 4

HH* 21838 Tee fitting .............................................................. 1

Hardware List

* These parts are not shown in the System Overview (Fig. 1).

**Photos show Load Lifter 5000 Ultimate Plus Kit.

STOP!

Tools List

MN-1127

Introduction

The purpose of this publication is to assist with the installation and maintenance of the Air Lift ProSeries and ProSeries

Ultimate air spring kits. All Air Lift ProSeries and ProSeries Ultimate kits utilize sturdy, reinforced, commercial-grade

single or double, depending on the kit, convolute bellows.

The air springs are manufactured like a tire with layers of rubber and cords that control growth. Air Lift ProSeries and

ProSeries Ultimate kits provide up to 5,000 pounds (2,268kg) of load-leveling support with air adjustability from 5-100

PSI (.34-7BAR).

It is important to read and understand the entire installation guide before beginning installation or performing any

maintenance, service or repair.

NOTATION EXPLANATION

Hazard notations appear in various locations in this publication. Information which is highlighted by one of these

notations must be observed to help minimize risk of personal injury or possible improper installation which may render

the vehicle unsafe. Notes are used to help emphasize areas of procedural importance and provide helpful suggestions.

The following definitions explain the use of these notations as they appear throughout this guide.

INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH.

INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH.

INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE TO THE MACHINE OR MINOR

PERSONAL INJURY.

DANGER

WARNING

CAUTION

MN-1127

Installing the System

CAUTION

IT WILL BE NECESSARY TO MOVE THE AXLE SPACER

BLOCK/JOUNCE BUMPER STRIKE PLATE FROM

ONE SIDE TO THE OTHER (FIG 3). THIS PROVIDES

CLEARANCE FOR THE AIR SPRING ASSEMBLY,

WHICH INSTALLS BETWEEN THE AXLE AND FRAME.

CARE AND SAFETY MEASURES MUST BE TAKEN TO

COMPLETE THIS TASK SAFELY AND SUCCESSFULLY.

1. With the vehicle on a hoist, block one tire in the front

and rear with chocks then lift the frame slightly to

take some pressure off the leaf springs (Fig. 2). Put a

safety stand under the front of the differential to keep

it from rotating.

Fig. 2

2. Mark the back side of each jounce bumper strike

plate/axle spacer for ease of reinstallation (Fig. 3).

Fig. 3

Back view of driver's (left) side differential

showing jounce bumper strike plate/spacer block

with mark for reference as stated in step #2

MN-1127

CAUTION

DO NOT RUSH THROUGH THESE NEXT STEPS. USE

ALL NECESSARY SAFETY PRECAUTIONS.

3. Remove the stock U-bolts on both driver's (left) and

passenger's (right) sides and discard. Lower the axle

assembly or raise the frame up slowly, far enough

to remove the jounce bumper strike plate/spacer

blocks from between the leaf spring and axle. Move

the driver's (left) side to the passenger's (right) side

and the passenger's (right) to the driver's (left) side

and install back between the leaf spring and axle (Fig.

4). Ensure that the mark on the back of the jounce

bumper strike plate/axle spacer faces the rear. The

strike plate should face the wheel, leaving the space

between the frame and axle open. Drop the frame or

raise the axle assembly slowly just far enough to hold

the jounce bumper strike plate/spacer blocks into

position.

NOTE

If the jounce bumper strike plate/spacer block is not

positioned correctly, the pinion angle will be incorrect and

may cause vibration while operating.

Fig. 4

Back view of driver's (left) side differential

showing jounce bumper strike plate/spacer block

with mark for reference as stated in step #2

4. Pull the jounce bumper out of the cup and unbolt the

cup from the frame (Fig. 5).

TECH TIP

Using a wire brush, brush the rust off the bolt protruding

through the weld nut on the frame. As much as possible,

reach into the hole on the inside of the frame rail, above

where the jounce bumper cup is bolted. Use penetrating

fluid on these bolts before attempting to remove.

Fig. 5

Fig. 6

5. Remove the driver's (left) side ABS line off the ABS/

brake line junction bolted to the axle (Fig. 6) and zip

tie (BB) the ABS line to the axle vent tube.

MN-1127

6. Mark the location noted in Fig. 7 and cut the end of

the bracket off using a hack saw or grinder with a cut

off wheel. This will make room for the lower bracket.

Fig. 7

7. Install a zip tie around the ABS/brake lines as shown

in Fig. 8.

Fig. 8

8. Remove the emergency brake line bracket from the

axle on the front, passenger's (right) side and discard

the bolt. Let the bracket hang at this time.

9. Install the upper frame brackets (C & D) onto the

frame using the M10 bolt (R) and flat washer (W)

(Fig. 9). Push the brackets against the frame and

torque the mounting hardware to (38 lb.-ft.) 52Nm.

Fig. 9

Driver's (left) side upper frame

bracket and hardware shown

C or D

MN-1127

10. Set a lower bracket (B) onto the passenger's (right)

side axle (Fig. 10) and insert the 5/16" hex cap screw

(O) through a 5/16" flat washer (U) through the lower

bracket, from the leaf spring side of the bracket, to

the inside (toward the center of the vehicle). Push the

bolt up against the bracket.

Fig. 10

11. Set the other lower bracket onto the driver's (left)

side. Position both lower brackets so they are up

against the leaf spring and jounce bumper strike

plate/axle spacer assembly. Set the U-bolts (G) into

position forward and rearward of the axle. Ensure

inside legs of both U-bolts go through the holes in the

lower bracket (Fig. 11).

NOTE

It may be necessary to trim the ABS/brake line bracket

previously modified if the lower bracket does not fit into

position without interference.

Fig. 11

12. Once the lower brackets are in position and the

U-bolts are in place, install the passenger’s (right)

emergency brake cable bracket onto the bolt

previously installed (Fig. 12) making sure the “tab” on

the bracket indexes in the space between the lower

bracket and axle. Cap with a flat washer (U) and

nylon lock nut (V). Leave loose at this time.

Fig. 12

MN-1127

13. Insert the carriage bolts (Q) down through the holes

in the upper bracket (Fig. 13), making sure the rear

carriage bolts go between the hard brake lines and

the axle (Fig. 14). Turn the heads of the carriage bolts

so they index into the square holes in the bracket.

Fig. 13

14. Raise the axle assembly or lower the body all the way

so that the leaf spring is supporting the vehicle. Set

the lower axle/spring retainer over the U-bolts and

cap with 9/16" flat washers (X) and 9/16" deep nuts

(S). Tighten finger-tight only at this time.

NOTE

Make sure the lower axle/spring retainer aligns with the

wear marks on the axle before torqueing U-bolts.

Install the lower clamp bar (A) over the carriage bolts

previously installed and cap with 3/8" serrated flange

lock nuts (T). Tighten finger-tight only at this time

(Fig. 14).

Fig. 14

15. In a criss-cross pattern, evenly torque the U-bolts to

90 lb.-ft. (122Nm). Once all the U-bolts have been

torqued, torque the 3/8" lower bracket axle clamp

hardware to 16 lb.-ft. (22Nm). On the passenger's

(right) side, securely tighten the emergency brake

cable bracket hardware previously installed.

NOTE

U-bolts must be retorqued after 100 miles.

MN-1127

ASSEMBLING THE AIR SPRINGS

1. Set a roll plate (H) onto the top of the air springs

(I) and install the fittings (J) into the top of the air

spring finger-tight. Tighten the fitting an additional

1 1/2 turns (Fig. 15).

Fig. 15

2. Insert a 3/8" carriage bolt (P) into the square hole

of the right-hand upper spring bracket (E) on the

opposite side of the tapered holes as shown in

Fig. 16. Set the bracket onto the air spring assembly

and install with two flat head screws (K). Torque the

screws to no more than 20 lb.-ft. (27Nm).

Fig. 16

3. Set the left-hand upper spring bracket (F) onto the

remaining air spring and attach with two flat-head

screws (K). Fig. 17 shows a picture of both left- and

right-hand assemblies ready to be installed.

Fig. 17

MN-1127

INSTALLING THE ASSEMBLIES

1. Lower the axle assembly or raise the frame

once again, just far enough so that the air spring

assemblies can be put in place between the upper

and lower bracket. Set the left- and right-hand

assemblies on the lower brackets (Fig. 18).

Fig. 18

2. While lifting up on the assemblies, insert two 3/8"

carriage bolts (P) up through the air spring bracket

and frame bracket (Fig. 19).

NOTE

The passenger's (right) side already has one of the 3/8"

carriage bolts installed.

Cap with the 3/8" serrated flange lock nuts (T). Torque

hardware on both sides to 31 lb.-ft. (42Nm).

Fig. 19

3. Set a roll plate (H) onto the lower bracket below the

air spring assembly (Fig. 20). Align the holes in the air

spring/roll plate/lower bracket as much as possible.

Raise the axle assembly up or lower the frame just far

enough so that the air spring sits on the lower bracket

(Fig. 21).

Fig. 20

Fig. 21

MN-1127

4. Insert a 3/8" hex cap screw (L) through a split lock

washer (M) and flat washer (N) then attach the air

spring to the lower bracket by inserting the assembly

up through the slot in the lower bracket (Fig. 22).

Push the air spring so that the hardware is to the

back of the slot and tighten the hardware securely.

TECH TIP

A 9/16" ratchet wrench works well in tightening this

hardware.

Fig. 22

5. Raise the axle assembly or lower the frame of the

vehicle. Remove the safety stands and wheel chocks.

6. Make sure there is enough clearance between the

carriage bolt and the brake line. Pull the line away if it

is hitting on the carriage bolt (Fig. 23).

Fig. 23

MN-1127

Installing the Air Lines

1. Choose the locations for the Schrader valves and

drill a 5/16" (8mm) hole, if necessary (Fig. 24). An

optional tee fitting (HH) has been supplied for those

who prefer to use just one Schrader fill valve on their

vehicle.

Fig. 24

A. Inside fuel tank filler door C. License plate or

B. Inside rear wheel wells rear bumper area

MICHIGAN

XXX-XXX

www.MICHIGAN.gov

A. B. C.

2. Cut the air line in half. Make clean, square cuts with

a razor blade or hose cutter (Fig. 25). Do not use

scissors or wire cutters.

Fig. 25

Good cut

Bad cut

CAUTION

KEEP AT LEAST 6" (152MM) OF CLEARANCE BETWEEN

ALL AIR LINES AND THE EXHAUST SYSTEM. AVOID

SHARP BENDS AND EDGES.

3. Use zip ties to secure the air line to fixed points along

the chassis. Do not pinch or kink the air line. Leave

at least 2" (51mm) of slack in the air line to allow for

any movement that might pull on the air line. The

minimum bend radius for the air line is 1" (25mm).

4. Install the Schrader valve in the chosen location

(Fig. 26).

5. Install the hose heat shield before installing the

passenger's (right) side hose into the fitting

(Figs. 27 & 29).

Hex nuts

Flat washer

Star washer

Rubber washer

Schrader

valve

Vehicle

body or

bumper

Nylon air line

to air spring

5/16” (8mm) hole

Fig. 26

Air line

thermal sleeve

Fig. 27

Hose heat

shield

MN-1127

INSTALLING THE HEAT SHIELD

1. Install the heat shield above the air spring assembly on

the inside pipe as shown in Fig. 28.

Fig. 28

2. Bend the heat shield up so that it is between the pipe

and the air line (Fig. 29 & Fig. 30).

Fig. 29

1/2” (13mm)

dead air space

between shield

and exhaust

Fig. 30

MN-1127

Finished Installation

The images show the finished installation of both sides (Fig. 31 - Fig. 34).

NOTE

Misalignment of the lower and upper air spring brackets are normal for this installation.

Driver’s (left) side behind the axle view. Fig. 31 Driver's (left) side inside above

the axle assembly view.

Fig. 32

Passenger's (right) forward axle view.

Fig. 33

Passenger's (right) inside above the

axle view.

Fig. 34

MN-1127

MAINTENANCE AND USE GUIDELINES

1. Check air pressure weekly.

2. Always maintain normal ride height. Never inflate beyond 100 PSI (7BAR).

3. If the system develops an air leak, use a soapy water solution to check all air line connections and the inflation

valve core before deflating and removing the air spring.

4. Upon successful completion of the installation, follow these pressure requirements for the air springs.

INSTALLATION CHECKLIST

 Clearance test — Inflate the air springs to 40-60

PSI (2.8-4.1BAR) and make sure there is at least 1/2"

(13mm) clearance from anything that might rub against

each sleeve. Be sure to check the tire, brakes, frame,

shock absorbers and brake cables.

 Leak test before road test — Inflate the air springs to

40-60 PSI (2.8-4.1BAR) and check all connections for

leaks. All leaks must be eliminated before the vehicle is

road tested.

 Heat test — Be sure there is sufficient clearance from

heat sources, at least 6" (152mm) for air springs and

air lines. If a heat shield was included in the kit, install

it. If there is no heat shield, but one is required, call Air

Lift customer service at (800) 248-0892.

 U-bolt - After 100 miles (161km), retorque U-bolts.

 Fastener test — After 500 miles (800km), recheck all

bolts for proper torque.

 Road test — The vehicle should be road tested

after the preceding tests. Inflate the springs to

recommended driving pressures. Drive the vehicle

10 miles (16km) and recheck for clearance, loose

fasteners and air leaks.

 Operating instructions — If professionally installed,

the installer should review the operating instructions

with the owner. Be sure to provide the owner with all of

the paperwork that came with the kit.

Maximum Air Pressure

Minimum Recommended

Air Pressure

100 PSI

7BAR

5 PSI

.34BAR

CAUTION

FOR SAFETY AND TO PREVENT POSSIBLE DAMAGE TO THE VEHICLE, DO NOT EXCEED MAXIMUM GROSS

VEHICLE WEIGHT RATING (GVWR) OR PAYLOAD RATING, AS INDICATED BY THE VEHICLE MANUFACTURER.

ALTHOUGH THE AIR SPRINGS ARE RATED AT A MAXIMUM INFLATION PRESSURE OF 100 PSI (7BAR), THE AIR

PRESSURE ACTUALLY NEEDED IS DEPENDENT ON LOAD AND GROSS VEHICLE WEIGHT RATING.

MN-1127

Limited Warranty and Return Policy

Air Lift Company provides a limited lifetime warranty to the original purchaser of its load support products, that the

products will be free from defects in workmanship and materials when used on cars and trucks as specified by Air

Lift Company and under normal operating conditions, subject to the requirements and exclusions set forth in the full

Limited Warranty and Return Policy that is available at www.airliftcompany.com/warranty.

For additional warranty information contact Air Lift Company customer service.

California: WARNING: Cancer and Reproductive Harm – www.P65Warnings.ca.gov

JJC-0620

Printed in the USA

Air Lift Company reserves the right to make changes and improvements to its products and publications at any time.

For the latest version of this manual, contact Air Lift Company at (800) 248-0892 or visit airliftcompany.com.

Air Lift Company • 2727 Snow Road • Lansing, MI 48917 or P.O. Box 80167 • Lansing, MI 48908-0167

Thank you for purchasing Air Lift Products — the Authorized Installer's choice!

Need Help?

Contact Air Lift Company Customer Service at (800) 248-0892

or email service@airliftcompany.com.

For calls outside the U.S. or Canada, dial (517) 322-2144.

Air Lift 94412 Installation guide

Air Lift 94412 Installation guide

Air Lift 94412 Installation guide

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